Wedge Assembly Bolt Retention for Reusable Tap Conductor Connectors
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Solution Overview
Problem
Existing electrical connector assemblies face challenges in securely and efficiently connecting main conductors to tap conductors, particularly in maintaining a reliable electrical and mechanical connection while allowing for easy assembly and disassembly.
Innovation Solution
The proposed solution involves a wedge assembly with a recess, first and second tabs, and a retainer mechanism, where the wedge assembly is configured to receive a main conductor or tap conductor, with the first tab extending into a cavity of a body member and the second tab engaging a bolt to drive the wedge into the connector, and a retainer secures the bolt to ensure a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shear bolt is used to tighten the clamping action, then the electrical and mechanical connection reliability is improved, but the ease of disassembly and reuse deteriorates
Solution Approach 1:
The bolt assembly is segmented into multiple functional components: the bolt itself, a retainer mechanism with engagement features, and a wedge assembly with tabs. This segmentation allows the bolt to be retained during assembly while enabling controlled removal for disassembly, resolving the contradiction between connection reliability and ease of disassembly.
Solution Approach 2:
The retainer mechanism provides dynamic retention of the bolt, allowing it to be securely held during the connected state while permitting removal when disassembly is required. This dynamic approach enables the system to transition between a retained state (for reliability) and a removable state (for ease of disassembly).
2Ease of operation
If the bolt is freely removable from the wedge assembly, then the ease of assembly and disassembly is improved, but the connection stability and security deteriorates
Solution Approach 1:
The retainer mechanism is pre-configured with engagement features that automatically secure the bolt upon insertion. This preliminary action ensures connection stability is established before the assembly process is complete, while still allowing for controlled removal when needed.
3Reliability
If a complex retainer mechanism is added to secure the bolt, then the connection reliability and reuse capability are improved, but the device complexity increases
Solution Approach 1:
The retainer mechanism is merged with the existing wedge assembly structure, where tabs and engagement features are integrated into the wedge body. This merging approach provides bolt security without adding entirely separate components, thereby reducing overall device complexity while maintaining reliability.
Data Source
AI summary
A wedge assembly may include a recess, a first tab, a second tab, and/or a retainer. The recess may be configured to receive a main conductor or a tap conductor when the wedge assembly is installed in an electrical connector. The first tab may be configured to be received by a cavity defined in a bottom portion of a body member of the electrical connector. The first tab and the second tab may define respective apertures therethrough that are configured to receive a bolt of the electrical connector. The bolt may be configured to drive the wedge assembly into the electrical connector such that the main conductor and the tap conductor are electrically connected. The retainer may be configured to releasably secure the bolt within the wedge assembly. The retainer may be configured to be removed to enable removal of the bolt from the wedge assembly.